Loop-pile-forming wires for looms



Oct. 1, 195? cs. T. STOVALL LOOP-PILE-FORMING WIRES FOR LOOMS I5Sheets-Sheet 1 Filed Jan. 20,1955

INVENTORI amaza ATTORNEYS.

1957 G. T. STOVALL LOOP- -PILE-F0RMING WIRES FOR LOOMS Filed Jan 20,1955 3 Sheets- Sheet 2 1 Q m I 7- I lNViE'INTOR: GEORGE THOMAS $TOVALL."

WARPWISE REPEAT WEFTWISE ATTORNEYS.

REPEAT Oct. 1, 1957 e. T. STOVALL LOOP-PILE- -FORMING WIRES FOR LOOMS 3Sheets-Sheet 3 Filed Jan.. 20, 1955 INVENTORI GEORGE THOMAS STOVALL.

.WARPWISE WARPWIS s WEFTWISE REPEAT ATTORNEYS.

United States Patent LOOP-PILE-FORMING WIRES FOR LOOMS George ThomasStovali, Spray, N. C., assignonby mesne assignments, to The New York'h'ust Company, a corporation of New York, and John H. Baile, SaddleRiver, N. J., as trustees Application January 20, 1955, Serial No.483,067

18 Claims. (Cl. 139-46) This invention. relates to looms for weavingloop pile fabrics and, more especially, to an improved method utilizingimproved longitudinal gauge wires or fingers adapted to extend throughthe dents of a loom reed for producing loops of varying heights.

There are various types of pile-forming wires or gauges currently in useon various types of looms for weaving loop and/or cut pile fabrics, suchas frieze, chenille and velvet plush fabrics, rugs and the like. In someinstances, weftwise extending Wires or gauges are used which may be ofuniform or variable heights throughout their lengths and which arewithdrawn from loops formed thereover as the fabric is woven. In otherinstances, longitudinal or warp'wise extending wires or gauges are usedwhich extend through the reed dents and weft yarns are passed over andunder the wires in succession. The

warpwise wires may be of uniform height throughout their lengths anddrawn forwardly with the fabric as it is woven and periodically movedrearwardly relative to the fabric to free them from the pile loops atthe free ends thereof.

The warpwise or longitudinal wires or gauges may also be of the typewhich are movable warpwise of the fabric individually, in groups, or intheir entirety, and which have a plurality of variant-height weavingstages adjacent the loop-forming ends thereof over whichpileloop-supporting weft yarns are cast.

The latter type of pile-forming wires or gauges as developed heretoforehave either had an inclined portion forming the weaving stages or thewires have been graduated in steps of different increasing heightstoward the rear of the loom. However, the latter type of gauges or wireshave necessarily had to be advanced at or less than the weaving rate ofthe fabric or drawn forwardly by the fabric itself as the fabric wasdrawn forwardly in weaving. This has necessitated the formation of loopsof gradually increasing heights between the terminus of a short-looparea and the forward end of a long-loop area having loops of asubstantially greater length than those in the short-loop area, so thatit has been impossible to produce a loop pile fabric having a distinctline of demarcation between the trailing end of a short-loop area andthe leading end of a long-loop area.

It is therefore an object of this invention to provide improved looppile wires, fingers or gauges for use in a loom and a novel method ofusing said wires wherein the wires are capable of being shifted quicklylongitudinally through the dents of the loom reed in both directionsduring the looping of pile yarn thereover to produce loops of varyingheight in any desired succession and wherein the pile wires may be soshifted at a speed independently of the speed at which the ground fabricis taken up by the loom so that all of the loops formed in any givenarea may be of uniform height relative to adjacent areas having loops ofdifferent height. This provides distinct lines of demarcation betweenloop pile areas' of different heights whereas, heretofore, it

has been necessary to advance the usual type of pile ice wires at orless than the rate of speed at which the ground fabric was taken up bythe looni which would result in indistinct lines of demarcation.

It is another object of this invention to provide im' proved pile wiresof the character described each having loop forming stages formed by twoor more vertically spaced prongs or projections on the free pile-formingend thereof fo'rming'a slot or slots therebetween through which pileyarn may extend. When the pile wires are shifted longitudinally of thefabric, the, lowermost prong projects forwardly beyond the front end ofthe prong th'ereabove or, in other words, the free front ends of theprongs terminate increasing distances from, the front end of the pilewire, so loops may be formed over any prong selectively'presented to theloop-forming zone of the loom. Thus, upon a pile loo'p or'loops beingformed over a prong other than the uppermost prong on a selected pilewire, the selected pile wire may be advanced at a speed faster than theweaving rate to immediately present a higher weaving stage or prong tothe loop forming zone, since the prong over which shorter loops werepreviously formed will advance through loops which had previously movedoff the free end thereof and the bights of a few of the shorter loopscould then extend through the slot between the prong over which theshorter loops were formed and the next succeeding prong thereabove.Thus, the loops formed on-the prong or projection at the higherelevation will be formed at a uniform height, as were the loops whichwere formed on the lower prong or projection, thereby obviatingthenecessity of providing loops of graduated heights at the juncture ofgroups of loops of two predeterminedly different levels. This enablesthe production of loop pile fabrics having loop pile areas of varyingheight and wherein each of the areas may be of any desired configurationand definite lines of demarcation would thus be formed between adjacentlow pile and high pile areas, for example, and so that ad jacent areasare sharply defined.

Some of the objects of the invention having been stated, other objectswill appear as the description proceeds when taken in connection withthe accompanying drawings, in which- Figure 1 is a somewhat schematicview showing some of the improved loop-forming fingers, Wires or gaugesin association with means for controlling the forward and rearwardmovement thereof on a loom;

Figure l-A is a view of a form of cam such as may be used in lieu of thecam in the lower right-hand portion of Figure 1 for controllingloop-forming fingers of the type shown in Figure 7;

Figure 2 is a fragmentary isometric view of a portion of an Axminstertype of loom showing the manner in which loops of varying'heights areformed over the prongs of one form of the improved pile wires or gauges;

Figure 3 is an enlarged fragmentary longitudinal or warpwise verticalsectional view through a portion of fabric showing the pile loops asformed by the form of the improved pile wire or gauge shown in Figure 6;

Figure 4 is a fragmentary transverse or weftwise sectional view throughthe fabric also showing the pile loops as formed over the form of theimproved loop-forming wire or gauge shown in Figure 6;

Figure 5 is a schematic illustration of a portion of fabric showingadjacent recessed and embossed areas of two different heights,respectively formed from relatively short and relatively long loops, butwherein said areas are shown in block form to clarify the relative shapeor configurationof adjacent areas;

Figure 6 is a view showing one form of improved pile wire or gaugeremoved from the loom;

Figure 7 is a view similar to Figure 6 showing another form of improvedpile wire or gauge; b

Figures 8 and 9 are views similar to the respective Figures 3 and 4showing loops of three different heights suchas may be formed with wiresof the type shown in Figure 7; I

Figure 10 is a view similar to Figure 5, but showing embossed andrecessed pile loop areas of three different heights.

Referring more specifically to the drawings, in Figures 1 and 2 portionsof a loom are illustrated, which loom is preferably of the Axminstertype equipped with pile wire or gauge controlling mechanismsubstantially of the type disclosed in the pending application of Ivar0. Moberg, Serial Number 398,287, filed December 15, 1953, and entitledMethod of and Apparatus for Weaving High and Low Pile Fabrics.

Generally, the apparatus disclosed in said pending application includesmeans for weaving a base or ground fabric from warp yarns and weft yarnsin the usual manner and is provided with pile yarn guides through whichrespective continuous pile yarns pass and which move downwardly from aposition spaced above the fabric, following the insertion of alternatedouble weft yarns through the open shed formed of the warp yarns andover the strands of pile yarn. Upon intervening double weft yarns beinginserted, the pile yarn guides move upwardly from a position within theshed and are then shifted laterally substantially simultaneously withthe beat-up stroke of the reed and then again moved downwardlypreparatory to another double weft yarn being inserted over the strandsof pile yarn. In so doing, the pile yarns are looped over respectiveloop-forming fingers, pile wires .or pile gauges provided with steppedloop-forming stages or free end portions of varying height and havingpattern controlled means for shifting selected fingerslongitudinalciation with other types of looms and other types of patterncontrolled means may be provided therefor, without departing from thespirit of the invention.

Referring particularly to Figure 2, the portion of a loom illustratedincludes a reed or beating-up means broadly designated at 10 andcomprising a reed box or lay 11 having a plurality of closely spacedreed splits 12 mounted thereon with openings therebetween, which arecommonly known as reed dents, and through which ground warps 13 and 13aare threaded. The ground warps 13 and 13a are controlled in the usualmanner by any suitable means, not shown, for forming a shed therewithand a suitable weft inserting means necessarily cooperates with the shedforming means in forming the fabric, the weft inserting means beingshown in the form of a weftwise reciprocable weft carrying needle 14, inthis instance, since the portion of the particular loom shown is that ofan Axminster type of loom. I

It might be stated that the weft carrying needle functions in the usualmanner to insert a double shot of weft yarn W in the shed following eachsuccessive beat-up stroke of the reed 10 as is clearlydisclosed in saidpending application and in various patents, such as Patents Nos.2,437,378 and 2,437,379 issued to Eugene F. Clark on March 9, 1948. Ofcourse, the usual type of shuttle and bobbin may be used with equalfacility for inserting a single weft yarn between successive beat-upstrokes of the reed 10, if desired. A

Referring to Figures 3 and 4, one form of loop pile fabric F is shownembodying pile loops formed in accordance with the present method. Asheretofore stated, the pile fabric base or ground is woven in the usualmanner; that is, the warp yarns 13 are spaced fillerwise or weftwise ofthe loom and serve as stuffer warp yarns adjacent each of which one ofthe warp yarns 13a is disposed. Thus, the warp yarns 13a, which arepreferably maintained under lesser tension than the yarns l3, serve asbinder warp yarns.

The fabric base shown in Figures 3 and 4 is woven by the so-calledtwo-shot cycle, method. Considering the fabric in Figure 3 as beingproduced from the left-hand side of the drawing toward the right, thewarps are opened with 13 up and 13a down, the filler or double weft yarnW would be placed through the warp and beat up. Since the stuffer warp13 is preferably taut as compared to the binder warp 13a and the stufferwarp 13 is above the filler W and the binder warp 13a is below thefiller W, when this shot of filler is beat up, it goes into the basefabric at a lower level than the next shot of filler.

In the next step the warp 13 is shedded down and the binder warp 13a isshedded up. The pile yarn is inserted into the shed by the guides 22, tobe later described, and a shot of filler W placed over the strands ofpile yarn, below the binder warp 13a and above the stutfcr warp 13. Asthe yarn guidesdescend into the shed, the pile yarn is looped over thecorresponding portions of the improved loop-forming fingers, to be laterdescribed, and is held in this condition until the shot of filler ismade and the needle 14 withdrawn from the shed, whereupon the guides 22ascend, drawing the shot of filler previously inserted over the pileyarn against the under side of the loop-forming fingers.

The filler or weft and pile loops are then beat up with the filler at ahigh level and the pile loops at a low level in the fabric, with thefiller against the base of the pile loops and the pile loops beat snuglyagainst the first-mentioned shot of filler. For the next step, thebinder. warp 13a is shedded down and the stuifer warp 13 is sheddedupward and the cycle of operation repeated as the fabric is woven, theimproved loop-forming fingers being provided with upper edge portions ofdifferent heights .for forming different lengths or heights of loopssuch as short loops S and long loops L.

The loom also includes a conventional transversely extending anddownwardly and forwardly inclined breast plate 16 for the support of thefabric, generally designated at F, after it has been woven.

The woven fabric passes from the breast plate and is taken up by asuitable take-up means shown schematically at 17 in Figure 2 and whichserves in the usual manner to maintain the fabric under constantpredetermined tension and which takes up the fabric as it is woven.

Pile yarns P extend downwardly from a point substantially above the reed10, under predetermined tension, and pass through respective eyes 21 inthe free lower ends of respective loop-forming pile yarn guides 22,there being a plurality of such pile yarn guides 22 disposed in closelyspaced relationship to form a row of said pile yarn guides'extendingtransversely of the loom.

The loop-forming pile yarnguides 22 may be of substantially the sameconstruction as, and operated by the same means as, disclosed in saidClark Patents Nos. 2,437,378 and 2,437,379. As disclosed in saidpatents, the movement of the pile yarn guides 22 into and out of thewarp shed and the movement of these guides laterally over theloop-forming fingers, wires or gauges to be presently described, therebyshogging the pile yarn over said fingers, is controlled by the operatingparts for the pile guides in relation to the operation of the needle 14as it places the filler or weft into the warp. Thus, a further detaileddescription of the beating-up means 10, the shed forming means, the weftor filler inserting means and the pile yarn guides 22 is deemedunnecessary.

Improved pile loop-forming fingers, gauges or wires In Figures 6 and 7,two forms of improved loop-formmg fingers, guides or wires are shownwhich are respectively designated at 25 and 26. Each of the-loop-formingfingers 25 and 26 is formed of a flat incompressible strip sufficientlythin to pass betweenadjacentreed splits of loop-forming finger 25 isshown in association with v the loom in Figures 1 and 2 wherein it willbe noted that the pile yarn guides 22 are adapted to pass between thecorresponding loop-forming fingers 25 in front of-the reed to carry thecorresponding pile yarns below the fingers and into the shed of the loomso that the needle 14 passes through the loops of pile yarn thus formedand positions double weft yarns between the warp yarns, over the strandsof pile yarn and below the fingers 25 and/or 26 in the usual mannersubstantially as disclosed in said Clark patents.

Referring again to Figures 6 and 7, it will be observed that the fingers25 and 26 have respective elongated shanl s-27 and 28 and the forward oroperating ends of the fingers 25 and 26 are each provided with aplurality of vertically spaced prongs or projections thereon. There aretwo such prongs or projections 31 and 32 shown on the finger 25. Themodified or second form of loopforming finger 26 is quite similar to thefirst form of finger 25 with the exception that it is provided withthree or more than two elongated prongs or projections thereon indicatedat 33, 34 and 35.

It is particularly important to note that the rounded front or free endsof the upper prongs in each instance terminate substantially short ofthe rounded free ends of the next succeeding prong immediatelytherebeneath. For example, it will be noted that the free end of theprong 32 terminates substantially short of the free end of the lowerprong 31 on the loop-forming finger 25 and, in the loop-forming finger26, the uppermost prong 35 terminates substantially short of the freeend of the intermediate prong 34 and the free end of the intermediateprong 34 terminates substantially short of the free front end of thelowermost prong 33. g

It is also particularly important to note that the prongs in eachinstance are disposed in vertically spaced relationship thus forming aslot 36 between the proximal surfaces of the prongs 31 and 32 of theloop-forming finger 25 and forming slots 40 and 41 between the lower andintermediate prongs 33 and 34 and the intermediate and upper prongs 34and 35 respectively, of the loopforrning finger 26. For purpose ofdescription, the portions of any of the prongs in either form ofloop-forming finger which extend forwardly beyond the free end of aprong immediately thereabove will be termed as the exposed portion ofthe corresponding prong or projection, and the exposed portions of theprongs of each wire may also be termed as loop-forming stages ofdifferent heights. The loop-forming stages are preferably of greaterheight than the width or thickness of the wires.

The loop-forming fingers 25 and/or 26 may be controlled by any suitablemeans, such as that disclosed in said pending application Serial Number398,287, as will be more fully described hereinafter, to selectivelyshift the loop-forming, fingers forwardly and rearwardly predetermineddistances so that, in the instance of using the loop-forming fingers 25,loops may be formed either over the exposed portion of the lower prong31 or over the prong 32 and, in the instance of the finger 26 beingused, loops may be formed over the exposed portions of either of theprongs 33 and 34 or over the prong 35. It is preferred, but notnecessary, that the upper surfaces of the upper prongs 32 and 35coincide with the upper surfaces of the shanks 27 and 28 of therespective loopforming fingers 25 and 26.

Now, assumingthat certain selected loop-forming fingers'25 are in arearward position relative to the'fell of the fabric being woven, to theextent that relatively short loops are formed from a pile yarn P overthe lowermost or bottom prong or projection 31, it follows that thecorresponding finger 25 may be advanced at a rate substantiallyexceeding the speed at which the fabric is taken up, in the course ofwhich the bottom prong 31 will merely move through loops which werepreviously formed thereover so that the bights of a few of the loopswhich were formed over the bottom prong 31 immediately preceding theforward movement of the loop-forming finger 25 will then be disposed inthe slot 36.

It is apparent that the free ends of the prongs or projections on bothforms of fingers are rounded or otherwise shaped so they will notensnare any of the previously formed pile loops as the prongs moveforwardly relative to the fabric. Thus, succeeding relatively long loopswill be formed over the upper prong 32 of each of the fingers 25 whichwere so advanced or moved forwardly, thus insuring a clear line ofdemarcation between the area of the fabric having the short loops Sthereon andthe area of the fabric having the long loops L thereon.

Of course, it is apparent that any fingers 25 which were advanced towhere the loops are formed over the upper prong 32 thereof may beselectively retracted or moved rearwardly, when desired, for againforming relatively short loops over the bottom prongs or projections 31.It is apparent that, when any of the fingers 26 are used, loops may besuccessively formed from the corresponding pile yarns P over any one ofthe prongs 33, 34 or 35 of any desired fingers 26 in any desiredsequence. For example, if short loops are formed over the lowermostprong 33, the slot 40 is of such depth that the corresponding finger 26may be advanced to where succeeding long or intermediate loops may beformed over either the uppermost or intermediate prongs 35 or 34,respectively, to produce a fabric such as that shown in Figures 8, 9 and10.

In Figure 5 there is shown one of many different types of pile looppatterns which may be produced by the improved method, using either ofthe types of loop-forming fingers shown in Figures 6 and 7 inassociation with a loom of substantially the character described. Thefabric F in Figure 5 includes a plurality of Warpwise spacedtransversely or weftwise extending and recessed zig-Zag lines or rows Rformed thereon from relatively short pile loops, said solid or embossedareas B being formed between adjacent transverse rows or recessed designareas R and being formed from relatively long pile loops. It will benoted that each weftwise repeat includes a stepped recessed area whichis substantially V-shaped, the stepped portions in each repeat beingindicated at a, b, c, d, e and f.

In weaving the particular pile loop area shown in'Figure 5, one or morepile yarns may be used in forming each of the short-loop or recessedareas a, b, c, d, e and y in each repeat, in this instance. Of course,the same number of pile yarns are used in forming the correspondingsolid, raised or embossed long-loop areas extending warpwise betweenadjacent rows R. Thus,- the loop-forming fingers 25 and/or 26 aredivided into sets, each including spaced groups of one or more adjacentfingers. The gauge wires weftwise across the loom may be of differentshapes, and the wires in each set may vary in length, height or designfrom each other and/or from the wires of other sets, if irregulardesigns or designs other 'than'as shown in Figures 5 and 10 are desired,such selection being a matter of choice.

Now, in order to control the fingers, it is preferable, but notnecessary, that a control mechanism substantially of the type disclosedin said pending application Serial No. 398,287 be used and, as stated insaid pending application, the loop-forming fingers in each set areattached to a corresponding finger holding and guiding bar, there beingfour such finger holding and guiding bars shown in Figure 1 eachdesignated at 45. For this purpose, each pile wire may be provided witha keyreceiving notch, such as indicated at 44 in Figure 2, or the rearend of each wire may be suitably apertured for connecting a controllingcord or cable thereto, if desired.

It will be noted that the finger holding and guiding bars 45 aredisposed in spaced parallel relationship and extend transversely of theloom or weftwise of the loom and the shanks 27 or 28 of the loop-formingfingers 25 or 26, as the case may be, each slidably penetrate all butone of the finger holding and guiding bars and are secured to thecorresponding finger holding and guiding bars so that those fingerswhose shanks are secured to a particular finger holding and guiding bar45 will be moved forwardly and rearwardly with only that. finger holdingand guiding bar 45 to which they are secured.

A separate pattern controlled means should be provided for each of thefinger holding and guiding bars 45, as shown in said pending applicationand, since the pat tern controlled means for shifting each of the fingerholding and guiding bars may be substantially the same, there is shownin Figure 1, means for controlling only one of the finger holding andguiding bars and it shall be understood that the same type of means maybe utilized for controlling each of the finger holding and guiding barsindependently of the others.

Each of the finger holding and guiding bars 45 has a guide block 46fixed thereon mounted for forward and rearward angular movement on aguide rod 47 suitably supported on the loom preferably at an angleconforming substantially to the angle of the breast beam 16. It is alsopreferable that the front portions of the shanks 27 or 28 of thecorresponding loop-forming fingers 25 or 26, as the case may be, areguided in a guide bar 50 suitably supported in fixed relation to theloom frame in back of the reed 10.

Although only one end of each of the finger holding and guiding bars 45is shown in Figure 1, it is to be understood that the, opposite endsthereof may be constructed and supported in the identical manner andopposite ends of each of the finger holding and guiding bars 45 have thefront ends of respective pairs of links 53 pivotally connected theretowhose rear ends are pivotally connected to the lower ends of respectivecrank arms 54. Only one of the crank arms 54 is shown in Figure l, butit is to be understood that the controls to be hereinafter described foreach of the pairs of crank arms corresponding to each of the fingerholding and guiding bars 45 may be identical.

It will be observed in Figure 1 that the crank arm 54 is fixed on arocker shaft 55 suitably journaled in fixed frame members 56 and 57which may be parts of the loom frame or may be suitably attached to theconventional loom frame. Another crank arm 60 is fixed on the rockershaft 55 and extends forwardly and is normally urged downwardly by atension spring 61. The front free end of the crank arm 60 has the upperend of a link or connecting rod 62 pivotally connected thereto whoselower end is pivotally connected to the front end of a cam lever 63having a follower 64 thereon which is urged against the periphery of acam wheel 65 by the tension spring 61. The cam wheel 65, as shown, isparticularly formed for controlling the two-stepped or pronged fingers25. Figure l-A shows a similar cam for controlling a three-pronged orthree-stepped finger 26.

The cam lever 63 is pivoted on a shaft 66 suitably supported by the loomframe. Formed integral with or fixed to one side of the cam wheel 65 isa ratchet wheel 67 and the cam wheel 65 and ratchet wheel 67 arerotatably vertically reciprocable ratchet pawl 71 which may be driven byany suitable means, not shown in the present drawings, but such as isclearly shown in said pending application.

The ratchet pawl 71 is normally urged into engagement with thecorresponding ratchet wheel 67 by a suitable spring 72 and one end of acontrol cable, strand or pliable element 73 is connected to the ratchetpawl 71 and extends rearwardly through a pair of spaced eyeboards oryarn guide boards 74 and 75 which may be parts of, or carried by, theconventional loom frame. The cable or cord 73 extends upwardly from theeyeboard 75 and is connected to a corresponding vibrator lever orpattern jack 76 which is a part of a suitable pattern mechanism, such asa dobby mechanism, broadly designated at 77 and which includes a drivenpattern chain 80. It is to be understood that there is a separate one ofthe vibrator levers or pattern jacks 76 for controlling the operation ofeach of the finger holding and guiding bars 45.

The pattern chain is of the usual type having high places or rollers 82thereon defining low places therebetween, which high places or rollers82 are spaced according to a predetermined pattern whereby, upon eachsuccessive roller or high place 82 engaging the corresponding vibratorlever or pattern jack 76, the pattern jack 76 is raised to thereby movethe ratchet pawl 71 out of engagement with the ratchet wheel 67 toprevent further rotation of the ratchet wheel 67 and the cam wheel 65until the roller 82 again moves out of engagement with the vibratorlever or pattern jack 76.

It will be noted that the cam wheel 65 in Figure 1 differs from thatshown in said pending application, to the extent that it is providedwith spaced high portions 65a thereon defining low portions or recesses65b therebetween. It follows, therefore, that when any one of the lowsurfaces 65b is in engagement with the follower 64 as shown in Figure 1,the bottom prongs 31 of the corresponding loop-forming fingers 25 wouldthen be in loopforming position such as that occupied by the threeloopforming fingers shown in the extreme lower right-hand portion ofFigure 2. On the other hand, upon engagement of the cam follower 64 byany one of the high surfaces 65a on the cam wheel 65, it is apparentthat the fingers 25 corresponding to the finger holding and guiding barcontrolled by the cam wheel 65 would then occupy advanced position inwhich the loops would be formed over the upper prongs or projections 32on the corresponding loop-forming fingers 25, such as that shown by thefingers in the lower left-hand portion of Figure 2.

Now, it is apparent that any of the finger holding and guiding bars towhich the fingers 26 of the type shown in Figure 7 may be attached couldbe controlled by a cam 81 (Figure l-A) which is similar to the cam buthas surfaces of three different heights thereon namely, high, medium andlow, and indicated at 81a, 81b and 310, respectively, instead ofsurfaces of two different heights thereon as shown in Figure 1. Thesethree surfaces of different heights may be arranged in any predeterminedorder according to the heights of the loops to be formed n a givensequence. Of course, the cam 65, as it is shown n Figure i, could beused for controlling the finger holdmg and guiding bars to whichloop-forming fingers 26 may be attached, but in this instance, only anytwo of the prongs could be used for forming loops of two differentheights, such as prongs 33 and 34 or 33 and 35 or 34 and 35.

Although the loop-forming finger 26 is shown as being provided withthree prongs 33, 34 and 35 thereon of varying length, it is to beunderstood that more than three prongs may be provided, if desired, inthe event that more than three different lengths or heights of loops areto be formed in forming a particular pattern.

In Figures 8, 9 and 10, there is shown one of many different types ofpile loop patterns which may be produced by the improved method, usingthe type of loopforrning finger or pile wire shown in Figure 7 inassociation with a loom of substantially the character described. Thefabric in Figure 10 is broadly designated at F-l and includes aplurality of warpwise spaced transversely or weftwise extending andrecessed double zig-zag lines or rows R-l, R2 formed thereon fromrelatively short pile loops and pile loops of intermediate length,respectively, with solid or embossed areas E-l being formed betweenadjacent or double transverse rows or stepped recessed design areas Rl,R2, and being formed from relatively long pile loops.

As is the case with the fabric shown in Figure 5, it will be noted thateach warpwise repeat includes a pair of stepped recessed areas which aresubstantially V- shaped, the stepped portions in each repeat and in eachrow Rl being indicated at a to f, inclusive, and the stepped portions ineach repeat in each row R2 being indicated at a" to f", inclusive. Also,as is the case with the fabric shown in Figure 5, in weaving theparticular pile loop area shown in Figure 10, one or more pile yarns maybe used in forming each of the short-loop or first recessed areas a tof, in each repeat, .and these same yarns may be used in forming thecorresponding intermediate-loop orsecond recessed areas a" to f" in eachrepeat, in this instance. Of course, the same number of pile yarns areused in forming the corresponding solid or raised long loop areasextending warpwise between adjacent rows R-l, R2. Thus, the loop-formingfingers 26.are divided into sets, each including spaced groups of one ormore adjacent fingers. 1

Assuming that the fabric F-1 is formed from left to right in Figure 10,it is apparent that the corresponding fingers 26 would assume a forwardposition in forming the long-loop area E-1 in the lower left-handportion of Figure 10, in which long loops would be formed over theuppermost prongs 35 of the loop-forming fingers or pile wires 26 shownin Figure 7. The fingers 26 corresponding to the areas a would then bewithdrawn to their rearmost positions so relatively short loops wouldthen be formed over the lowermost of the corresponding prongs 33. Itfollows that, as the areas b, and c, e and d are formed, thecorresponding fingers 26 would also be withdrawn to rearmost positionsso short loops are formed in the corresponding areas.

Of course, as the corresponding portions of the areas b, c, d, e and areformed, it is apparent that selected fingers 26 would also moveforwardly to intermediate positions, in the course of which previouslyformed short loops in the corresponding row R-l would be penetrated bythe lowermost prongs 33 on the corresponding loopforming fingers or pilewires 26 so the bights of the last few loops successively formed in theareas a and b, f and c, eand I) would successively extend through theslots '40 between the corresponding intermediate prongs 34 and thelowermost prongs 33. Thus, intermediate loops would be formed over theintermediate prongs 34 to successively form'the areas a" and b", 1" andc", d" and b" in the next succeeding row R2.

Of course, as each of the last-named areas in the row R-2 is completed,the corresponding loop-forming fingers 26 are again advanced to theirforemost positions so the bights of the last few loops formed over theintermediate prongs 34 will then extend through the'slots 41 between thecorresponding uppermost prongs 35 and the intermediate prongs 34; Thus,relativelylong loops will be formed overthe then active high prongs 35to form the second high loop area E-l to complete one warpwise repeat inthe forming of the loop pile fabric F-l.

'Referringnowto Figures 8 and-9, it is shown more in detail just how theloops of three diflerent-heights are formed on the fabric base. As isthe case in weaving the fabric base or ground shown in Figures 3 and 4,warp yarns 13 are spaced fillerwise or weftwise of the loom and serve asstuifer warp yarns adjacent each of which one of the binder warp .yarns13a is disposed, each of the binder warpyarns 13a. preferably beingmaintained under lesser tension than the yarns 1 3. I i

The fabric base shown in Figures 8 and 9 is also woven by the so-calledtwo-shot cycle method and, considering the fabric in Figure 9 as beingproduced from left to right, the warps are open with 13 up and 1311'down, the filler or double-weft yarns W would then be placed through thewarp and beat up. The stuffer warp 13 being taut as compared to thebinder warp 13a, when this shot of filler is beat up, it goes into thebase fabric at a lower level than the next shot of filler. In the nextstep, as is the case in the fabric shown in Figure 3, the warp 13' isshedded down and the binder warp 13a is shedded up. The pile yarn isinserted into the shed by the guides 22 and a shot of filler W placedover the strands of pile yarn, below the binder warp 13a and above thestufier warp 13.

As the yarn guides descend into the shed, the pile yarn is looped overthe corresponding portions of the loop-forming fingers, which portions,in this instance, are the lowermost prongs 33 of the fingers 26, and isheld in this conditions until the next shot of filler is made and theneedle 14 withdrawn from the shed, whereupon the guides 22 ascend,drawing the shot of filler previously inserted over the pile yarnagainst the under side of the loop-forming fingers. It is apparent thatthis is successively repeated and, while the fingers 26 are in rearwardposition, relatively short loops 8-1 are formed thereover and, when thecorresponding loop-forming fingers 26 are in the intermediate position,intermediate loops I are formed as are present in the rows R2 in Figure10.

It is apparent, by a comparison of the intermediate loops I and theshort loops 8-1 in Figures 8 and 9, that the lower prongs 33 may readilyenter or move longitudinally in the loops S1 as the intermediate prong34 passes over the last few loops S-l adjacent the intermediate loops I,thereby insuring that the intermediate loops I are subsequently formedover the intermediate prongs 34 on the corrseponding pile wires 26.Referring again to Figure 9, relatively high loops L-1 are illustratedand it is apparent that these loops are formed by advancing thecorresponding loop-forming fingers 26 to a fully forward position soboth the intermediate and lower prongs 34, 33 advance within theintermediate loops I and the upper prong 35 advances above the loops Ito thereby insure that the upper prong 35 is positioned for theformation of the long loops L-l thereover, forming areas such as thearea E-1 in the fabric F.

It is thus seen that I have provided an improved loopforming methodutilizing improved loop-forming fingers adapted to be associated with aloom for weaving loop pile fabrics such as rugs, carpets and the likeand wherein the loom is provided with means for selectively shifting theloop-forming fingers longitudinally of the warp and wherein the improvedloop-forming fingers are provided with elongated vertically spacedprongs thereon of varying length over whose free end portions loops ofcorresponding heights may be respectively formed and whereby, upon loopsbeing formed over any one of the prongs of a particular finger having aprong thereabove, the finger may be moved forwardly, quickly, relativeto the loops previously formed thereover to cause the bights of thepreviously formed loops to extend through the slot defined between thecorresponding prong and the prong immediately thereabove so thatsucceeding loops of any accurately predetermined greater height than thepreviously formed loops may then be formed over the prong above saidcorresponding prong or over any prong which may be disposed on a higherlevel than'said cor responding prong.

It is apparent that this provides means whereby the major portion of afabric, for example, may be formed with relatively ion-g pile loops withvariantly-shaped design areas formed from loops of an intermediateheight and other variantly-shaped design areas being formed with loopsof still another height and wherein each of the areas formed from anyone of the heights of loops will stand out sharply and thereby providinga definite and dis tinct line of demarcation between areas formed fromdifferent height loops.

The appearance of the loop pile fabric thus produced is particularlyenhanced because it is no longer necessary to provide loops of graduatedheights at opposite ends of a given area having loops of one givenheight and wherein other areas having loops of another height aredisposed at opposite ends of said given area.

It is contemplated that the principles of the present invention; thatis, pile wires having a plurality of prongs or loop-forming stages ontheirfree ends with slots therebetwcen and means for shifting the wiresforwardly, at a speed faster than the fabric is woven, and rearwardly topresent different height surfaces to the loop-forming zone, may beapplied to many different types of looms in addition to the type of loomheretofore described. Such pile wires may be used in a doup heddlc loom,a needle motion doup heddle loom, a double-shuttle loom wherein twofabrics are woven simultaneously, a Warner-Swasey projectile loom, anAshofi leno reed loom of the type manufactured by Steel HeddleManufacturing Company of Philadelphia, Pennsylvania, and other types oflooms.

Of course, pile loops are usually formed directly over or under the pilewires when using a loom of the type disclosed in the present drawings orwhen using a doup heddle loom or a Warner-Swasey projectile loom.However, in a double-shuttle loom, for example, the different prongs orloop-forming stages may support weft shots which, in turn, support thepile loops as they are formed between adjacent pile wires and wherebythe loop-supporting weft shots may subsequently be removed forseparating the fabrics.

Also, if desired, selected loop-forming fingers or 26, as the case maybe, may be entirely withdrawn from the loop-forming zone so the pileyarn would then bear against the fabric base rather than being formedinto loops and, thereafter, these fingers may be advanced to present anyone of the prongs thereon to the loop-forming zone to produce a novelloop fabric.

Inoperation, it has been found that, when the prongs on the pile-formingfingers are relatively long, loops may initially be formed directly overselected prongs as the corresponding pile yarn guides 22 move across andabove the level of the loop-forming fingers and then downwardly into theshed, after which a shot of filler is placed through the warp and overthe strands of pile yarn. The pile yarn guides then move upwardly as thelatter shot of filler is heat up by the reed 1 As each shot of filler isheat up, the loops are slid forwardly on the corresponding prongs towardthe fell of the ground fabric. Since the pile yarn guides do not moveforwardly with the reed, the loops are then drawn tightly over thecorresponding loop-forming stages or prongs.

On the other hand, when the prongs on the pile-forming fingers arerelatively short, regardless of the position of any of theseloop-forming fingers which are not completely withdrawn from theloop-forming zone, loops may initially be formed over the body portionsor shanks of those fingers in the loop-forming zone so that eachsuccessive loop formed on each finger is subsequently slid along thecorresponding shank with the succeeding beatup stroke of the reed 10 andis tightened or drawn taut as it passes off the shank and onto thecorresponding loop-forming stage. Thus, the height of each successiveloop is finally determined by the height of that prong disposed inactive or operative position.

In either instance, there are usually approximately four loops presenton the free front end portion of each of those loop-forming stages orprongs which is in active or loop'height-determining position. The lastformed or rear'rnost of these four loops is pulled taut while theimmediately preceding three loops, which were previously pulled taut,serve to guide and steady the free front ends of the correspondingloop-forming fingers.

In the drawings and specification there have been set forth preferredembodiments of the invention and, although specific terms are employed,they aroused in .a

of limitation, the scope of the invention being defined in the claims.

I claim:

1. In a loom having a reed and other means for making cloth,longitudinal pile gauge wires having free end portions extending throughthe reed dents, individual wires of said pile wires having a pluralityof loop-formingstages of different heights which may be predeterminedlypositioned above the cloth during weaving, said individual gauge wireseach having slots therein between adjacent loop-forming stages, andmeans for quickly moving said individual gauge wires forwardly relativeto the cloth, to position different loop-forming stages of differentheights to the fell of the cloth at predetermined intervals.

2. .A structure according to claim 1 wherein the lower slots in eachinstance terminate rearwardly of all loopforming stages thereabove.

3. In a loom having a reed and other means for making cloth, and alsohaving means for looping pile yarn over longitudinal pile gauge wires;the combination therewith of longitudinal pile gauge wires extendingthrough the reed dents, individual wires of said pile wires having aplurality of loop-forming stages of different heights which may bepredeterminedly positioned above the cloth during weaving, saidindividual gauge wires each having slots therein between adjacentloop-forming stages, and means for moving said individual gauge wiresforwardly relative to the cloth and rearwardly of the cloth to positiondifferent loop-forming stages of different heights to the fell of thecloth at predetermined intervals.

4. An'improved pile loop-forming finger for use with a loom for weavingloop pile fabric and wherein said loom is provided with means forlooping pile yarn over each loop-forming finger and means for shiftingthe loopforming finger longitudinally of the warp, said improvedloop-forming finger comprising an elongated relatively thin strip ofincompressible material having at least two vertically spaced elongatedprojections on its free forward end defining a slot therebetween, andthe forward end of the uppermost projection being spaced substantiallyrearwardly of the forward end of the lowermost projection.

5. A structure according to claim 4 wherein at least the lowermostprojection is shaped at its free forward end to permit forward movementof the latter projection relative to and within previously formed pilcloops.

6. In a loom having a reed and other means for making fabric and alsohaving means for looping pile yarn over longitudinal pile gauge wires;the combination therewith of longitudinal pile gauge wires extendingthrough the reed dents, individual'wires of said pile gauge wires hav'ing a plurality of loop-forming stages of different heights which may bepredeterminedly positioned at that position where pile loops aretightened in the fabric during weaving, means for moving said individualgauge wires longitudinally of the fabric to position different stages ofdifferent heights at that position where pile loops are tightened in thefabric at predetermined times, and said individual gauge wires eachhaving longitudinally extending slots therein extending rearwardlybetween adjacent stages of different heights whereby said individualgauge wires maybe moved forwardly, upon pile loops being formed over anyof said stages of different heights, at a rate exceeding the' rate atwhich the fabric is woven and the bights of any loops formed over any ofthe stages of different heights other than the uppermost of said stagesmay extend through the corresponding slots as the correspondingindividual gauge wires are so moved forwardly.

7. In a loom having a reed and other means for making cloth and alsohaving means for looping pile yarn over longitudinal pile gauge wires;the combination therewith of longitudinal pile gauge wires extendingthrough the reed dents, individual wires of said pile gauge wireshavingtwo or n 1 ore elongated vertically spaced prongs on the freeforward end ,t l re rej4:vf, the prongs above the lower.- Inost of saidprongs terminating progressively increasing distances from the freeforward end of the lowermost g ss to orm st ps at 'difistem a. isht whicm b predeterminedly positioned adjacent the fell of the cloth, n means fr m v n sa ind vidua s u wires -itiudinal y o the lot i i h r di ect nndep ndent y of the rate at which the cloth is woven whereby upon loopsbeing formed over any prongs other than the uppermost prong, saidindividual gauge wires may be advanced within previously formed loops sothe bights of some of the previously formed loops may extend through thecorres ending space between adjacent prongs as loops are subsequentlyformed over another prong thereof to permit the formation of loop pileareas having a distinct line of demarcation betweenloops of differentheights.

;8 In a loom having a reed and other means for making cloth,longitudinal pile gauge wires having free end portions extending throughthe reed dents, individual wires of said pile wires having a pluralityof loop-forming stages of different heights which may be determinedlypositioned in the cloth during weaving, said individual gauge wireshaving slots therein between adjacent loop-forming stages, and means forquickly moving said individual gauge wires forwardly relative to thecloth to position different loop-forming stages of dilferent heightsadjacent the fell of the cloth at predetermined intervals.

9. In a loom having a reed and other means for making cloth,longitudinal pile gauge wires having free end portions extending throughthe reed dents, means for laying pile-supporting weft shots past saidgauge wires, said loom also having means for looping pile yarn over saidpile-supporting weft shots, individual wires of said pile wires having aplurality of loop-forming stages of different heights which may bepredeterminedly positioned longitudinally of the cloth during weaving,said individual gauge wires having slots therein between adjacentloopforming stages, and means for quickly moving said individual gaugewires forwardly relative to the cloth to position different loop-formingstages of different heights adjacent the fell of the cloth atpredetermined intervals.

10. In a loom having a reed and other means for making cloth, means forlaying pile-supporting weft shots beneath longitudinal pile gauge wires,and also having means for looping pile yarn over said pile-supportingweft shots; the combination therewith of longitudinal pile gauge wiresextending through the reed dents, individual wires of said pile wireshaving a plurality of loop-forming stages of different heights which maybe predeterminedly positioned above the cloth during weaving, saidindividual gauge wires each having slots therein between adjacentloop-forming stages, and means for moving said individual gauge wiresforwardly relative to the cloth and rearwardly of the cloth to positiondifferent loop-forming stages of different heights to the fell of thecloth at predetermined intervals.

11. In a loom having a reed and other means for making cloth,longitudinal pile gauge wires having free end portions extending throughthe reed dents, individual wires of said pile wires having a pluralityof loop-forming stages of different heights which may be completelywithdrawn from, and predeterminedly positioned in, the cloth duringweaving, said individual gauge wires having slots therein betweenadjacent loop-forming stages, and means for quickly moving saidindividual gauge wires forwardly relative to the cloth to positiondifferent loopforming stages of different heights adjacent the fell ofthe cloth at predetermined intervals.

12. In a loom having a reed and other means for making cloth and meansfor forming loops from pile yarns, longitudinal pile gauge wires havingfree end portions extending through the reed dents, individual wires ofsaid pile wires having a plurality of loop-forming stages of differentheights which may be predeterminedly positioned at and completelywithdrawn from active position relative to the loopeforming ,rnean sduring weaving, saidindividual sense r s ea h-ha in slots t i t ee adiea loop-forming stages, and means for quickly moving said individualgauge wires forwardly predetermined distances relative tothe cloth toselectively position looprforming stages of difierent heights in activerelation to the loop.- forming means at predetermined intervals.

13. A .structure according .to claim 12 wherein the lower slots in eachinstance tenninate rearwardly of all loop-forming stages thereabove.

1 4. In a loom having a reed andother means for making clot-h fromground warp and weft yarns, and also means for looping pile yarn overwarp and weft yarns; the combination therewith of longitudinal pile.gauge wires extending through the reed dents, individual wires of saidpile Wires having a plurality of loop-forming stages of differentheights which may be predeterminedly positioned above and rearwardly ofthe cloth during weaving, said individual gauge wires each having slotstherein between adjacent loop-forming stages, and means for moving saidindividual gauge wires forwardly relative to the cloth and rearwardly ofthe cloth to, at times, position different loop-forming stages ofdifferent heights to the fell of the cloth at predetermined intervals.

15. In a loom having a reed and other means for making fabric from warpand weft yarns and also having means for looping pile yarns over warpyarns and beneath weft yarns; the combination therewith of longitudinalpile gauge Wires extending through the reed dents, individual wires ofsaid pile gauge wires having a plurality of loop-forming stages ofdifferent heights, means for moving said individual gauge wireslongitudinally of the fabric to, at times, predeterminedly positiondifferent stages of different heights at that position where pile loopsare tightened in the fabric, and said individual gauge wires each havinglongitudinally extending slots therein extending rearwardly betweenadjacent stages of different heights whereby said individual gauge wiresmay be moved forwardly, upon pile loops being formed over any of saidstages of different heights, at a rate exceeding the rate at which thefabric is woven and the bights of any loops formed over any of thestages of different heights other than the uppermost of said stages mayextend through the corresponding slots as the corresponding individualgauge wires are so moved forwardly.

16. In a loom for weaving pile fabrics, said loom having means formaking a base fabric from warp and weft yarns including a reed andadditional means for forming loops from pile yarns in which the pileyarns are shogged across warp yarns and anchored to weft yarns of thebase fabric; the combination of longitudinal pile wires having free endportions movable through the reed dents, individual wires of said pilewires having a plurality of loopforming stages of different heights,said individual wires having slots therein between adjacent stages, andmeans to move said individual wires warpwise in either directionrelative to the base fabric to selectively position wires entirely awayfrom the point at which said pile yarns are shogged and to selectivelyposition different loopforming stages of different heights at saidpoint.

17. In a loom having a reed and other means for making cloth,longitudinal pile gauge wires having free end portions extending throughthe reed dents, means for laying pile-supporting weft shots past saidgauge wires, said loom also having means for looping pile yarn over saidpile-supporting weft shots, individual Wires of said pile wires having aplurality of loop-forming stages of different heights which may becompletely withdrawn from and predeterminedly positioned in the clothduring weaving, said individual gauge wires having slots therein 0between adjacent loop-forming stages, and means for quickly moving saidindividual gauge wires forwardly relative to the cloth to selectivelyposition certain wires so that different loop-forming stages thereof ofdifferent heights are positioned in the vertical plane of correspond- 5ing pile-supporting weft shots at predetermined intervals.

18. In a loom having a reed and other means for making cloth from warpand Weft yarns and also having means for looping pile yarns over warpyarns and under weft yarns; the combination therewith of longitudinalpile gauge wires extending through the reed dents, individual wires ofsaid pile gauge wires having two or more elongated vertically spacedprongs on the free forward end thereof, the prongs above the lowermostof said prongs terminating progressively increasing distances from thefree forward end of the lowermost prong to form steps of differentheights which may be predeterminedly positioned adjacent the fell of thecloth, and means for moving said individual gauge wires forwardly andrearwardly relative to the fell of the cloth independently of the rateat which the cloth is woven whereby loops may be formed against thecloth and over selected prongs and upon loops being formed over anyprongs other than the uppermost prong of any of the wires, the lattersuch wires may be advanced within previously formed loops so the bightsof some previously formed loops may extend through the correspondingspace between adjacent prongs as loops are subsequently formed overanother prong of the latter wires to permit the formation of loop pileareas having distinct lines of demarcation between loops of differentheights.

References Cited in the file of this patent UNITED STATES PATENTS1,790,832 OLena Feb. 3, 1931 2,318,080 Keen May 4, 1943 2,437,378 ClarkMar. 9, 1948 FOREIGN PATENTS 36,870 Germany Sept. 16, 1886

